Operators Manual Model # AB, RTF, ABS, · PDF fileOperators Manual Model # AB, RTF, ABS, ABS2...
Transcript of Operators Manual Model # AB, RTF, ABS, · PDF fileOperators Manual Model # AB, RTF, ABS, ABS2...
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Operators Manual
Model # AB, RTF, ABS, ABS2
May 2010
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Notes:
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Index
Basic Operations and Operator Interface (HMI) Guide
Brine Batch Production 5-9
Home screen Graphics
Water Level & Concentration Graph 10
Liquid Flow 11
Batch Information/Animations 11
Eutectic Curve 12
Data Log 13
Tank Farm 14
Remote Truck Fill - RFID Operation 15-17
Warning Beacon 18
Recycled Water 19
Faults 20-23
Roll Tarp Operation 24-25
Inline Salt Tank Heater Operation 26
Parts 27
Advanced Operations and Machine Configuration
High Level Passwords 28-29
Remote Truck Fill - RFID Setup 29-32
Additive System - Blended Products 33-38
Additive System - Recirculation, Tank Transfers 39-40
Recycled Water Setup 41
Machine Set Up
Page 1 - Brine production 42-46
Page 2 - Storage Tanks, Air Purge, Forcing valves, 47-52
Remote Truck Fill, Inline Salt Tank Heater,
Page 3 - Additive Injection, Micro Ingrediant, 53-55
Crossover Activation
Operating Modes 56
Switch Box 57
Accubrine Plumbing Configuration Drawings 58-61
Help Page 62
Save/Reload My Settings 63
Data Downloads from HMI 64-68
Accubrine Data Manager Tool Installation 69-74
Using the Accubrine Data Manager Tool 75-78
Date and Time 79
HMI Care and Maintenance 80-84
Compact Flash Card 85-87
LAN Access/Web Gate 88-94
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Index Continued:
Start Up Procedure 95
Parts
Main Control panel and Pump 96-98
Salt Tank Parts 99-106
Clamps & Gaskets 107
Storage Tank Plumbing Kit and Level Sensor 108
Roll Tarp 108
Modular Panel Example 109
Electric Valves 110-112
Preventative Maintenance Schedule 113
Trouble Shooting Guide 114-115
Conductivity Analyzer Single Point Calibration 116-117
Conductivity Analyzer 3 Point Calibration 118-119
Auto/Manual Valve Positions and Operation 120-121
Cleaning Salt Tank & Sump 122
Off Season Storage Prep. 123-125
Complete Parts List 126-133
Manufacturer Warranty 134-135
Warranty Claim Form 136
Warranty Claim Instructions 137
Return Materials Authorization Form 138
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Caution: To produce a batch of product. The machine must be in Normal or Winter-
ize mode. Use Simulate mode for training only. See Operating Modes section.
To access the Batch page, set
Password to 10.
Press the Batch Button to
produce brine.
Producing A Brine Batch
To Change the password
press the help button.
Then Press the Password
button.
By Pressing the Password
button, a key pad appears as
shown. Key in 10 and press
the Enter button.
Press the Escape button
to go back to the HOME
page.
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Select a Job to record Data to by
pressing the Select Job Button.
A pop up window appears as
shown below.
Press the desired Job to record
data to from the pop up
window.
The selected Job will appear
in red.
Note: Through out this
manual, when a button is
pressed and turns red, that
feature has been Activated.
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Press the setup button to name
each Job.
A pop up window appears as
shown below.
Select the Job 1 button and a
keyboard display will appear.
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Type in the name of the desired
Job on the keyboard and press
enter.
The name entered will be dis-
played as shown. Do this for each
Job as desired. When finished,
push the ESC button to stay at the
Batch page.
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To start producing Brine. Press
the Job Select button and select
specific job if desired.
Key in the desired quantity of brine
to produce via key pad then press
the ENTER button.
Press the Green Total Volume
button on the batch page to select
the quantity of brine to produce.
To Stop a batch at any time, either press the Stop button on the display from the Batch Page or use the
Auto /Hand Switch and momentarily rotate to Hand and back to center.
Press the ESC button then press
the Auto Start button from the
display or use the Auto / Hand
switch on the panel by rotating to
Auto and releasing.
The available volume indicator
shows how much brine can be
made and sent to the brine storage
tank.
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If the Auto start button was
pressed then the display will
change to the main screen.
If the Auto / Hand Switch
was used to start the batch
press the Home button to
return to the HOME screen.
ESC to go to previous page.
Or
Understanding the
HOME Screen
Concentration Below Target
(Weak Brine)
Concentration Over Target
(Strong Brine)
Concentration At Target
(Good Brine)
The Gray shaded area in the yellow, shown below is a visual for
the water level in the salt tank. The blue dots above the yellow salt
tank represent water flow to the salt tank. When the red line
above the salt tank turns blue, there is fresh water flow to the salt
tank.
The green rectangle
represents the acceptable
concentration with devia-
tion.
The right edge of the red
line represents the actual
concentration.
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As brine is being produced. The
animation on the screen illustrates
what is occurring with the machine.
(see call out numbers)
1. Brine is over-concentrated and is
being diverted to Salt Tank.
2. Fresh water is flowing to the Salt
tank.
3. The Dilute valve is opening to
dilute the over concentrated brine to
the desired concentration.
As seen to the left:
1. Brine is within tolerance.
2. Water is flowing to the Salt tank.
3. Product Flow is to Storage tank 1.
4. Batch is approximately 75% com-
plete.
5. Data is logged to Job 1 & the batch
size is 2,000.
6. The system is in Simulate Mode
(See Operating Modes section).
7. Material build up in Sump is
indicated in Red.
8. Recycled Water (If feature is in-
stalled) is flowing to the salt tank.
1
2
3
4
3
1
2
567
8
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By touching the concentration meter, a
pop up window appears to illustrate
the eutectic point of Salt Brine.
Touching the 23.3% button gives
specifics on brine at it’s eutectic
point.
Press the ESC button to close the
window.
Salt Concentration and Eutectic Curve
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Data Log: The machine will
record the amount of Brine
produced, water, recycled water,
additives and salt used in sepa-
rate logs that are associated with
the Job.
By pressing the Data Log button
on the HOME page, the screen
to the left appears.
To reset the Daily log, press the Reset Daily Log button. Daily data may be reset to zero at any time.
Note: You must select each job individually to reset to zero.
The Season log keeps a running tally of production and may only be reset with a high level password
activated (see High Level Password section). The Reset Season Counter button will only be visible when
the high level password is activated.
Data Log Report
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Storage Tank Farm
The Tank Farm page shows the storage tanks installed and the current volumes in each tank. To access this
page, press the tank farm button on the Home page.
The 1 in the green box indicates that
tank number 1 ( brine storage) is
installed for this system.
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Graphics of HOME screen illus-
trating Remote fill in operation:
Filling Truck from the Brine Stor-
age tank.
Graphics of HOME screen illus-
trating Remote fill in operation:
Filling Truck from Blended Product
Storage tank.
Remote Truck Fill and RFID (if installed)
The Remote fill feature allows trucks to be filled at the touch of a button from a remote switch box. Upon
activation, product is diverted to the truck from the Salt tank (if making brine), Brine storage tank or
Blended Product storage tank, without the operator needing to open or close valves and start pumps.
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HOME screen graphics illustrating
the Remote Truck Fill system in
operation during a brine production
batch. Filling the truck with fresh
brine from Salt Tank when the
brine concentration is within the
specified range.
When an attempt to fill a truck
with the remote fill is made during a
Blended Product batch, a notice
will pop up stating that the Blended
batch must complete before truck
filling is allowed. It is possible to fill
a truck with Blended Product
during a Brine batch. The brine
batch will pause to allow the truck
to be loaded. The brine batch will
then continue from where it was
interrupted.
Remote Truck Fill and RFID Operation (if installed) cont.
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Remote Truck Fill and RFID Operation (if installed) cont.
The Tag ID number represents
the RFID tag that was read by the
RFID card reader. The volume
will count up as the truck is being
loaded.
The RFID system uses RFID tags to identify what truck is receiving product, when the truck was loaded,
what product the truck received and the volume loaded. This data is recorded and stored for use when
desired. The system can be set up to load a specific product, a maximum volume, and prevent loading if an
ID tag does not match, for security purposes. See RFID Setup Section.
The RFID card reader and Truck fill operation switches are combined in one enclosure. The card is passed
in front of the reader here. A beep will be heard to indicate the card has been read.
An emergency stop switch is
provided and will stop pump.
The green indicator light will
light up when an RFID card
has been scanned. The light
and ID tag will stay active for
45 seconds after turning the
switch to stop. This allows
the truck to be topped off if
needed.
A digital readout will indicate
number of gallons being
loaded. (see pg. 54 for
display value offset)
The truck can then be loaded
using the start stop switch.
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Warning Beacon
The Warning Beacon red strobe light will blink steadily with a machine fault. If the salt tank runs
out of salt (user defined on set up page 1) and the specified brine concentration cannot be met
within 30 minutes, the light will blink for 5 seconds and turn off for 5 seconds and repeat. When
a scheduled automatic start occurs, such as winterize mode, and automatic tank fill, the beacon
will blink for one minute prior to machine start. The illustration below shows the Warning Bea-
con.
The Warning Beacon displaying the fault mode will turn off when the machine faults have been
corrected and acknowledged from the faults screen. Note: If after 4 hours, the faults have not
been corrected and acknowledged, the light will turn off automatically.
The Warning Beacon displaying the Salt Tank Out of Salt mode will turn off when the machine is
restarted.
Deactivating the Warning Beacon:
The warning beacon should be installed in a location easily visible to the operator. See example
below.
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Recycled Water
The recycled water system uses recycled or grey water from other processes such as storm run off or truck
wash water to make brine. The brinemaker will automatically switch to fresh water when the recycled
water level in the storage tank reaches the minimum level.
To view the level of recycled water in
the storage tank, press the green Tank
Farm button on the Main screen.
The Tank Farm page shows the
Recycled Water tank with the
minimum level, and the current tank
volume.
When a batch is started, the Main
page shows the Recycled Water
pump has turned on, and the re-
cycled water is being sent to the salt
tank.
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Machine Fault The machine is constantly monitoring valves and sensors. If a sensor or valve
fails, the machine will shut down and a fault will appear on the main page.
Press the blinking Fault Page
Button to view the fault.
The fault button will turn red
indicating what failure has
occurred.
For example: The machine had
a fault with the tank valve. By
pressing the fault page button,
you are led to this fault page.
At this point the Tank valve
fault button would be red.
Press the red fault button for
possible solutions to the prob-
lem. For example:
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A pop up window will appear
to give basic trouble shooting
tips and what fuse to check.
If this does not solve the prob-
lem and a part needs to be
replaced then press the green
PART BUTTON.
Once the problem is corrected
press the RESET BUTTON
located in the center of the fault
page.
Note: It is possible to ignore or disable alarms. This is helpful in
diagnosing a problem and if the device is operating correctly but
the sensing circuit has failed. Ignore the alarm by pressing the
disable alarm button.
Once the Part button is
pressed, the display will show
where the part is located with a
blue circle.
The part number will be in
the blue box. Some parts have
more detailed drawings and are
illustrated via a green expand
button.
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Expanded view of Tank Valve.
After a machine fault occurs, a log is created of that fault and is displayed on the Summary of Faults page.
From the HOME page
press the HELP button
Press the Summary of Faults
button in the lower left
corner.
To access the Summary of Faults
page, press the HOME button.
Summary of Faults
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To clear and acknowledge the
fault, press the acknowledge
button.
The summary of fault page
gives the time and date of a
fault along with a description.
The red lines illustrate when the
fault occurred. The green lines
illustrate when the fault was
corrected.
Summary of Faults Page
Press the HOME button to return
to HOME page or.
Press the ESC button to return to
previous page.
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Roll Tarp Operation
The handle for operating
the tarp is stored on the
“J” hook. Unhook and
turn handle to unroll the
tarp towards the front of
the salt tank.
The Roll Tarp is used to keep debris such as leaves from entering the salt tank, and when the inline heater is
used to keep the salt tank from freezing.
When the Roll Tarp is not
being used, it can be rolled
up on the steel support pipe
and rested on the supports
mounted on the back, top lip
of the salt tank.
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Roll Tarp Operation Cont.
After unrolling the tarp,
the handle should be
replaced on the “J”
hook to store.
To open tarp, unhook handle and roll tarp back towards rear of salt tank until it rests on the supports.
If the tarp becomes dirty, clean with mild soap and water.
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Inline Salt Tank Heater
The Inline Salt Tank Heater is used when the liquid inside the salt tank is in danger of freezing. The heater is
activated to run automatically when the Winterize Mode is selected (See Operating Mode section).The
heater may be run manually as well (See Inline Salt Tank Heater Setup section).
Above the green Mode button, you
will see the Winterize Mode has been
activated. The preset timer to recircu-
late the salt tank will come begin.
When the timer reaches the prescribed
time, the warning below will be visible
on the screen.
The temperature sensor for the heater will
sense the liquid and if the temperature is
lower than the ON temperature setting, the
heater will turn on. The heater will stay on
until the liquid in the salt tank reaches the
preset temperature limit. After the heater
turns off, the Winterize mode will resume
counting down until the next cycle.
Before the pump turns on, a Caution
will popup stating the Winterize process
will begin in one minute. After one
minute, the pump will start the recircula-
tion process.
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Parts and Mechanical Items
To view the various parts on the machine (salt tank and control panel) Click on the parts button on the
bottom of the HOME page. You will be directed to the Parts Selection page. Select the desired area to find
the part.
Other parts may be called up
at any time. Key in the desired
number from the drawing into
the green box located in the
lower right corner. To key in a
value, touch the green box. A
key pad will appear. Key in
the value that corresponds with
the parts diagram and press
enter. The selected part will
appear with a red circle around
that part.
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HOME page with 0 (Zero) as the
password. Note: The only function
available with password 0 activated
is the data log.
To Change the password press
the help button
Then Press the Password button
There are 4 passwords that allow different functions
Password 10: Allows for basic operation.
Password 20: Same as 10 with the added ability to Force Product from tank to tank.
Password 4096: Allows set up of machine settings.
Password 2048: Allows for set up of the Display, capturing current machine settings, retrieving data to USB
port, and using video if installed.
PasswordsThe system is protected by various passwords that allow different levels of function.
Key in desired password on
the keypad and push enter.
29
By Pressing the Password button, a
key pad appears as shown. Key in
desired password and press the
Enter button.
Press the Escape button to go back
to the HOME page.
Remote Fill Settings from Batch page with password 4096 activated
From the Batch page, the operator
can activate the Remote Truck fill
operation by pressing the Remote
Fill Activated button.
To select what product to fill trucks
with, select the Tank 1 - Brine, or
Tank 2 - Blended Product, Addi-
tive 1 or Additive 2 tank (if in-
stalled).
To lock out the Truck fill remote switch for times when not in use and
for security, press the REMOTE FILL LOCK OUT BUTTON. This
will protect the system from vandalism.
Note: The password will revert
back to 10 after 45 seconds or you
return to the HOME page.
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Remote Truck Fill and RFID Setup
The Truck Fill and RFID system can be set up to fill trucks with or without RFID tags, deliver a specific
product to the truck and a maximum volume based on which tag is used. To access the RFID set up page,
enter password 4096
Press the RFID Truck
Loadout button
This will bring up the
RFID setup page.
To activate the RFID system, enter
password 4096 and go to the setup
page 2. Press the RFID On button.
It will turn red when active.
31
To setup the RFID page, first pass one RFID tag in front of the card reader. Two numerical values will be
displayed in the blue code box.
Type in the yellow code number
displayed in the blue code box
when the keypad pops up.
Note: The actual tag
number in red is the same
number written on the
RFID tag.
Press the yellow “Tag 1” to name the
RFID tag just swiped. It is suggested
to use the last five digits of the card
number and for example, Truck #6.
Press the green Tag ID
code button.
Remote Truck Fill and RFID Setup cont.
Press the green Load Out Product
button and a selection menu will
appear. Use the up and down arrows
to select which product (brine, blend,
additives 1 or 2) to assign to the tag
just entered.
Press the blue Maximum Volume button and enter a maximum
volume delivered to a truck every time that card is read. When
this volume is reached the pump will shut off.
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Remote Truck Fill and RFID Setup cont.
To activate or deactivate the Tag Match, Tag to Product, and Maximum Volume features. Press the buttons
listed below. The buttons will turn red and switch to “On” to activate. Press again to deactivate.
Truck fill operates without RFID tag. Truck fill operates only when an RFID tag is
used and has been setup on the RFID page.
Operator must select which tank/product to
deliver to the truck fill from the Batch page.The correct product, selected earlier,
is delivered to the truck fill.
Operator decides how much
product to deliver to truck.
Truck fill will stop pumping when the
Maximum Volume is reached.
The RFID system will allow up to 40
different RFID tags to be setup.
Press the green RFID Setup 11-20
button to access tags 11-20.
When this button is pressed, the
next 10 tags will be available for
set up.Note: All Tag ID Code positions must have a 1
in the green box if a tag code is not entered.
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Producing a Blended Product Batch
Enter the desired total quantity
of Blended Product to produce
by pressing the Total gallons
button.
Enter a numeric value to
represent desired additive ratio
(% of total volume).
Enter a Value between 0-100,
for example for 20% additive
and 80% brine, key in 20.
Press the ENTER BUTTON
A key pad will appear. Key in
numeric value of product to
produce then press the
ENTER BUTTON.
To select the desired ratio of Additive as a percent of total product to add to the brine, press the %
Additive button
A blended product is a custom mix of another additive(s) in conjunction with the salt brine.
Desired Ratio of Additive
34
Tank 2 will always be the Blended
Product tank mixing vessel. If an
additive Ratio is between
1-100% & tank 1 is the se-
lected tank then a warning will
appear as shown to inform to
switch to the Blended Product
tank or tank 2.
To change to tank 2 for a Blended
Product batch press the Tank 2
button.
The button will turn red and the
warning will disappear.
The information in the blue
box is information as it relates
to a Blended Product.
The value to the right of the
Volume button is the available
volume in tank 2. This is the
maximum quantity of material
that may be produced before
the tank will overflow.
Is the quantity of Additive
available in the Additive
storage tank.
35
The machine will calculate the
correct quantity of material to be
produced given the total volume
and Ratio and each will be dis-
played in the progress graph
below.
In this example: A batch of 500 units was entered with a ratio of 20%. The machine calculates the quantity
of each material to produce, 400 units of brine and 100 units of Additive will be mixed to produce a
Blended Product.
The machine will first produce 1/2 of the desired brine, from the above example 200 units / 2 = 400 units
and then add 100 units of Additive 1 then add the remaining 200 units of Brine.
The graphics change on the
display as the additive is being
added to the Blended Product
tank.
Press the Auto Start button
Graph showing brine
being produced.
36
If it is desired to put Blended
product into the Brine tank, select
tank 1, a warning will appear (as
shown on left).
It is not possible to produce a
standard Blended Product between
1 - 99 % and divert to Tank 1.
You must select 100% additive,
and a volume then press Auto
Start. You can then produce a
Brine batch into the Brine tank to
produce the nonstandard blended
product.
Non Standard Blend and Brine Batch Production
The Brine storage tank may be used to store a Blended product.
The illustration to the left
shows that 100% additive is
flowing to the Brine Storage
tank.
37
If it is desired to put Brine product
into the Blended tank, select tank 2
and warning will appear (as shown
on left). To continue, press the
start button and brine will be sent
to tank 2
The illustration to the left
shows that 100% Brine is
flowing to the Blended
Product storage tank.
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Premature Shut down If a Blended Product batch is stopped prior to completion due to a machine
fault or operator interference, the machine will inform on the batch page, as to the new batch size and ratio
required to complete the last incomplete batch. To resume the batch, go to the batch page and key in
suggested batch size and ratio and restart batch.
To finish the incomplete batch, the
new volume will be 117 units at
32% ratio. When this new batch
size is completed, the original batch
of 150 units at 25% ratio will be
complete.
For example: A batch of 150
units was started at 25% ratio of
additive 1 and the operator turned
the machine off prior to comple-
tion.
39
Additive System Recirculation .
To activate the recirculation
for an additive, select the
Recirculation 1 additive or
Recirculation 2 additive
button.
To set up the additive system to
recirculate product tanks, go to
set up page 3.
The recirculation for Additive 2 has been activated in the illustration
above.To set up the “ON” time and “OFF” time for
storage tank recirculation, press either the Tank
Agitation Schedule or Recirculation buttons.
Select which storage tank
to recirculate.
The button will turn red and
turn to “ON”.
40
Touch the Hours Off and Minutes On buttons to set up
the recirculation schedule for each tank desired. The
example to the right shows the storage tank will
recirculate for 20 minutes every 24 hours. If multiple
tanks are scheduled, one tank will recirculate and then
continue with the next tank.
To recirculate a storage tank manually, touch the
Manual Recirculate button. The recirculation will
continue until the Stop Manual Recirculation button
is pressed or the Remote Truck fill switch is acti-
vated.
FORCE TRANSFERS OF LIQUIDS
To move liquids between storage tanks, such as brine to blended product, go to the Force Transfer page
with password 4096 active.
Press the Batch button.
Press the Force Transfer
button.
Select the button that
corresponds to the
liquids you want to
transfer.
In this case, 500 gallons of Blend product is being transferred to the Brine storage tank.
Press the Stop Transfer button
if you want to stop the transfer.
Starting a batch or operating
the truck fill will also stop the
transfer.
Press the Target button and enter the volume of liquid to transfer.
Press the Start Transfer button to begin the liquid transfer.
41
Recycled Water Setup
This machine has the capability (if installed) to use a recycled water and fresh water supply to dissolve the
salt to produce brine. The three way electrically actuated valve and auxilliary pump is controlled by the
Control Panel to use the recycled water until the volume in the storage tank reaches a user defined minimum
level. The actuated valve then changes position to allow fresh water to continue the brine making process.
To access the Recycled Water tank settings, enter password 4096, press the Tank Farm button on the
Home page.
Press the Recycle Water
button to ACTIVATE and set
storage tank calibration, and
minimum volume levels.
Press this green button to
enter the tanks maximum
volume. The keypad for the
Recycled Water tank will be
displayed. This value should
be approximately 5 percent
less than the tank capacity.
This value will leave enough
liquid in the tank to prevent
the pump from running dry
before the control panel
switches to the fresh water
source. When the liquid level
in the recycled water storage
tank is above this Min level,
the recycled water will be
used.
Press the Min Level button
to set the low liquid level.
Press this green button to
enter the calibration value.
This value correlates the
liquids pressure being read
by the transducer to volume.
The value can be moved up
or down to reflect actual tank
volume.
The Recycled Water tank setup is now complete. The brinemaker will use recycled water when the level is
above the Minimum volume and revert to the fresh water source when below the Minimum volume.
42
Machine Set Up Page 1
To access Set Up page from the HOME page, press HELP then press ENTER PASSWORD, key in
password of 4096 then press ENTER then press ESC to go back to the HOME page. The Set Up button
will be at the bottom of the page.
Press the SETUP button to
access set up page 1.
Set up page 1
Page 1 set up has basic machine
settings for brine production only.
By pressing the green text
button by each setting, a descrip-
tion of the setting appears. Press
the Dilute Valve Acceleration
Multiplyer button below for an
example.
43
Target Brine Concentration: This setting is the desired target concentration of the salt brine. Set this to
the concentration that is desired. Units are in % salt divided by % total weight.
Target concentration + or -: Concentration of brine that is considered acceptable. By changing the value
in the red box, the corresponding number to the right changes. The value + or - is 1/2 of the overall per-
centage therefore, if the values are 224 and 0.4% and the target concentration is 23.3%, the acceptable
brine would be 23.3% + or - .2% or 23.1 to 23.5% concentration by weight.
A popup window describing the
Dilute Valve Acceleration
Multiplyer appears.
Machine Set Up Page 1 Cont.
Dilute Valve Auto Adjust: This setting is used to automatically adjust the dilute valve to regulate brine
concentration. This function OVERRIDES the Dilute Valve “ON”, Dilute Valve “OFF”, Dilute Valve
Acceleration, and Dilute Valve Multiplier settings.
Press the far right green button and enter a value that determines the number of clicks it
takes for the valve to fully open. In this case, 15 clicks will open the valve fully. This is the
factory setting.
Press the middle green button to start the “Auto Calibration” of the dilute valve. The valve
will self calibrate until the valve opens in 15 clicks.
44
Low Level Shut Down: Is the amount of time before the machine shuts down if minimum concen-
tration is not met. Time value is in minutes set between 10 & 30.
Dilute Valve Acceleration Multiplier: This value speeds up the valve by __ times to speed the valve up
if the concentration is outside of tolerance + or - .
Adjust this setting to 1 if the valve speed is fast and it may be raised to 2 if the valve speed is very slow.
Adjusting this value above 1 can cause hunting, however if fine tuned correctly can make the machine ramp
up more rapidly.
Dilute valve Acceleration at %: Is the deviation from the concentration where the dilute valve will
increase speed if the concentration is outside of this tolerance. For example: If the target concentration is
23.3% and the deviation is 833 then the valve would increase speed if the actual concentration is (833/56)
therefore 23.3% + or - 1.4% (56 units moves .1%). Setting this value to low will make the machine hunt.
Dilute valve on time Period: Adjust the speed of which the dilute valve adjusts itself. The higher the value
the faster it opens. Lower values slow the valve down. This is a critical setting and should be custom fit to
the machine. Over time this value may need to be changed to adjust for wear on the machine. If the value
is to high, the concentration of the brine will begin to hunt over and then under the specified concentration.
If the value is to low, the dilute valve may never open. Note: depending on the speed of the valve, this
number may be between 5 and 100. Units are in milliseconds.
Dilute Valve Off Time Period: This value is the amount of time after an adjustment of the dilute valve
before it adjusts itself again. Setting this value to high, the process will become slow. Setting the value to
low can cause the machine to hunt. Units are in seconds, suggested values 2-5.
Machine Set Up Page 1 Cont.
Press the “OFF” Dilute Auto Adj. green button to ACTIVATE the “Auto Adjust” feature of
the dilute valve. This will OVERRIDE the Dilute Valve “ON”, Dilute Valve “OFF”, Dilute
Valve Acceleration, and Dilute Valve Multiplier settings.
This button will turn red when the feature is activated.
45
Salt Tank Water Level: These values determine the
point at which the pump turns On and Off, and controls
the water level in the salt tank. The values in red represent
the water level in inches above the sensor on the salt tank.
Select each green button for description of function.
Pump off level: This is the low level limit. Adjust this to protect the pump from running dry. Value nor-
mally will be 6-10” or 14.5 - 24.0 cm if conversion factor was set to 25.
Pump on Level: This is the level where the pump turns on. This value must be higher than Pump Off Level.
For systems with high flow, a value of around 14” is a good starting point..
Water Off Level: Adjust the maximum quantity of water that will be added to the salt tank. Keeping this
value low will reduce overflow when adding salt. This value must be greater than Pump on level.
Winterize ON Time: Is the amount of time that brine is recirculated between the control panel and the
salt tank. Value is in Seconds.
Winterize Off Time: Is the amount of time between recirculating cycles (Winterize ON Time). Value is in
Hours.
Flow Volume: Flow rate is the units per minute that the machine is producing in a brine only (non-Blended
Product) going to Tank 1 or (brine storage tank). Upon initial calibration, set at 107 for units without
modular panel set at 90 for units with modular panels. If amount produced is less than actual, lower the
value. If amount produced is more than actual, raise the value.
Brine Sensor Calibration Value: This is a correction value for the conductivity analyzer. If actual
brine concentration is weaker than the machine indicates, lower the value. If concentration is stronger than
target, raise the value. Base line setting is 10 (value of 10 there is no correction).
Conversion Factor: Select 1 for standard measurements in inches, or select 25 for metric measurements
in centimeters.
Machine Set Up Page 1 Cont.
46
Reset season Counter: Resets the current activated data log or Job size to zero. Each job
must be selected and reset individually.
Reset Sump Clean Out: Resets the warning on the salt tank and the full sump indicator turns
from red to blue to indicate a clean sump. Press this button and reset after clean out of the
salt tank.
Material Other Than Salt: This setting calculates the theoretical amount of sediment in the salt tank. Esti-
mate the amount of foreign material in the salt and key the value as a percentage in here. The lower the
value the less often the salt tank will need to be cleaned.
Transducer Range: This setting is the maximum pressure reading on the transducer located on the salt tank.
Units are in PSI. Standard reading is 7.2.
Reset Batch: Resets the batch size to zero. Use this if that machine locks up and a batch size
can not be entered.
Reset Daily Counter: Resets the current activated data log or Job size to zero. Each job
must be selected and reset individually.
Machine Set Up Page 1 Cont.
47
Machine Set Up Page 2
Storage Tank Set Up
Remote Truck Fill
Air purge
Forcing main control panel valves & pump
Inline Salt Tank Heater
Controller Status
Accumulated Production
Press the Number of Tanks
button and enter the number
of installed storage tanks
with pressure transducers on
the key pad and press enter.
Press the Storage Tank
Setup button to view tank
setup page.
From setup page 1, select the
Setup Page 2 button..
Press the Transducer Type-
Brine Storage On button to
select pressure transducer
for the brine storage tank.
Activating this button over-
rides the Normally Open or
Closed buttons used for a
float switch.
48
Machine Set Up Page 2 Cont.
Press the Name Tank Set Up
button and enter the name for
each installed tank on the key-
board and press enter..
Key in the desired name for each
storage tank. Note: with an additive
injection system the default name of
Tank 1 is dedicated to Brine and
Tank 2 is dedicated for Blended
Product. Name the tanks appropri-
ately. For example Tank 1 (default
name) to Brine 6,000 Gal & Tank 2
(default name) to Blended Product
80/20 6000Gal.
Remote Truck Fill
Option: If Remote
Truck fill is installed,
Select the Auto fill
button to activate the
appropriate programing
and funtionality for the
Remote Truck fill feature.
49
Machine Set Up Page 2 Cont.
Air Purge SetupThis is used to set the amount of time that the air purge will open the solenoid valve to purge the water line
between the control panel and the salt tank. Units are in seconds. The Air Purge activates each time the
machine is shut down. It is recommended to have approx. 90 psi and a 1/2” unrestricted supply.
Select the Air Purge
Setup button.
Enter a value, in number of seconds for
the Air Purge to stay on. Increase
number if fresh water hose does not
purge enough of the water.
Forcing Operation: This should only be done for trouble shooting or for manually overriding the
machine for non standard operation such as troubleshooting a valve. Under normal operation, the Auto
button should be Red. To move liquids, the machine must be running then press the desired force button.
When the machine is stopped or started, the forcing buttons will be reverted back to AUTO. Forcing
valves or pump may damage machine and / or cause machine to operate erratically.
Force pump on: Forces the pump to run regardless of machine
operation and liquid level in the system.
Force Tank Valve Open: Forces the tank valve open to divert
flow to the storage tank in a standard machine. With the modu-
lar panel, it forces product to the modular manifold outlet bank.
Force Dilute valve: Opens the dilute valve momentarily as long a button is
pushed. This will allow fresh water to enter into the pump inlet and into salt tank
and /or output flow.
Force water Valve: Forces the water valve open to
allow fresh water flow to the Salt tank.
50
Inline Salt Tank Heater Setup
To access the settings for the Inline Salt Tank Heater, enter password 4096 and go to setup page two.
Select “Off” if heater is not
installed.
Select “Auto” if heater is
installed and it is desired to
have heater turn on automati-
cally as needed via thermostat
in Winterize Mode.
Forces the Heater ON. “Caution must be used”. The liquid inside the heater must be recirculat-
ing to prevent overheating and possible damage.
Select the U.S. Fahrenheit or Metric Celsius button based on the machines wiring diagram
and which input is used for the thermostat. Input 0 is for Fahrenheit, and Input 1 is for
Celsius.
Heat On Temp: Is the Temperature at which the heater will be turned ON if HEATER AUTO
is selected. Touch the red numeric value to adjust the setting.
Heat OFF Temp: Is the Temperature at which the heater will be turned OFF after it has been
turned on (from above), if HEATER AUTO is selected. The heater turns on at the set point
above and will heat the liquid until it reaches this point. Note: If AUTO is selected, this value
must be greater than the ON setting. Touch the red numeric value to adjust the setting.
Heat Alarm Set Point: This is the point at which an alarm will illustrate the low temperature
warning on the salt tank. Set this value at or below the ON temperature.
Machine Set Up Page 2 Cont.
51
Machine Set Up Page 2 Cont.
The Controller Status page displays information about the status of valves, pressure transducers, pump, and
other systems on the brinemaker. It can be used as a tool to troubleshoot these items as well as view
operational information and force valves open.
The legend shown at left describes the color
indicators and their meanings.
The table to the left shows output numbers for
pressure transducers and the conductivity
analyzer. The numbers are from 0 to 4095
(full scale) representing the 4 to 20 milliamp
reading from each item. For example: The
1129 for the Additive 2 Tank means that the
output is about one quarter of full scale and
the tank should be approximately one quarter
on the HMI touch screen. The items reading
zero are either: not installed, installed incor-
rectly (wiring), have no liquid in the storage
tank, or have failed.
52
Machine Set Up Page 2 Cont.
To force a valve open and check for proper operation, touch the
green NORMAL button for the valve you want to open.
The button will turn red and state FORCE ON. The CLOSE
indicator has changed fro green to red indicating the valve has
opened.
The Average Brine Concentration indicator shows the concentration
of the brine produced per batch. It will reset and begin again with
each new batch.
53
Additive systems Micro Ingrediants
Storage Tanks Recirculation / Tank Agitation
Cross Over
Press to select the appropri-
ate button below to activate
a 1 additive, or 2 additive
system.
The maximum volumes, calibration values and
names for the liquid storage tanks can be setup
here or the Tank Farm page.
Select the No Additive
System button if there is not
an additive system installed.
Set Up Page 3
Storage Tank Setup
Press the green button to enter the maximum volume of the Blended Product storage tank. It is recom-
mended to enter a volume 5% less of the total volume to prevent the tank from over filling.
Press the red button to enter the calibration value for the storage tank. It is recommended to enter a value
of 1 to start. When a known volume of liquid (IE: 1000 gallons) is in the storage tank, adjust the calibration
value up or down to accurately reflect the actual volume.
Continue this process for the Additive 1, and the Additive 2 storage tanks if applicable..
The storage tank setup can be done on the Tank Farm page as well. From the Main/Home page, select the
Tank Farm button.
54
Set Up Page 3 Cont.
Press this green button to enter the tanks maximum volume. This value should be
approximately 5 percent less than the tank capacity to prevent overfilling.
Press this green button to enter the calibration value. This value correlates the
liquids pressure being read by the transducer to volume. This value can be moved
up or down to reflect actual tank volume.
Storage Tank Setup from Tank Farm
Press this green button to enter the name of the storage tank if desired.
The Tank Farm page shows all
the storage tanks applicable to
the type of system selected. For
example: A 2 Additive system
without Recycled Water has
been selected here.
Enter the name, maximum tank volume, and calibration factor for each storage tank.
RFID Digital Display Setup
Press the RFID Display Offset button if the display number is off from the actual volume
delivered. For example: When filling a truck, the touch screen shows 250 gallons were
delivered to the truck. The card reader display shows 245 gallons were delivered. Press the
RFID Display Offset button and enter 5. This will correct the displayed value on the card
reader to 250.
Press the RFID Display Cal. Factor button if the display number is off from the actual
volume delivered. This cal factor multiplies the Offset factor by the value entered here. For
example: Offset value 5 X Cal factor 1 = 5. (Note: This number will typically stay at 1)
55
The Crossover is used for a 1 or 2 additive system to prevent small amounts of additives from being sent
into the salt tank during the blended product process. After the additive is added to the blended product
tank, the crossover keeps the three way tank valve open to the blended product tank for (in this case, 6
seconds) until brine flushes the valves and plumbing.
Press the crossover button to activate this feature. Press the button to the right of
the crossover to enter a value in seconds. (5 or 6 seconds is recommended)
Press the Micro Ingrediant button to access the setup page.
OR Press the Recirculation or Tank Agitation button to access the
setup page. (See pages 39 - 40)
Set Up Page 3 Cont.
Select which product to add the Micro Ingrediant
to. Select the Reset button to turn off the addition
of the Micro Ingrediants to the products.
Select which product/s to add Micro Ingrediants
into while filling trucks. Select the Reset button to
turn off the addition of the Micro Ingrediants while
filling trucks.
Micro Ingrediants
Micro Ingrediant Option: The Micro Ingrediant Option injects trace amounts of micro ingrediants into the
finished product. These could include anti-foaming agents, dyes etc. Press the Micro Ingrediant Option
button to go to set up page.
Press this button to enter the pump flow in units per minute. This example is set at 1.6
gpm. Use key pad and press enter when completed. Note: Pump flow may be found
on pump label.
Press this button to enter the desired ratio of Micro Ingrediant per units of
product. Note: You must use like units. For this example, 1.6 gallon of
additive per 5,000 gallons of product. (Refer to manufacturers label for correct
ratios)
Press button to manually prime pump. Depending on length of supply tubing, this may
take several minutes to prime.
56
Operating Modes
Normal Operation Mode: Machine is able to make brine, and do other production and delivery functions
with options equipped on machine.
Winterization Mode: Machine starts timers that are setup for recirculating the salt tank, storage tanks and
inline heater. When Brine and Blend products need to be produced, or when the Remote Truck Fill is
started, the Winterize Mode will be paused. Winterize Mode will resume when the batch is complete or
truck fill is shut off.
System Rinse Mode: Machine flushes out the main control panel and pump with fresh water. Caution:
Close suction/brine out valve on salt tank and remove hose to brine storage tank to prevent fresh water from
entering storage tank before activating mode. Lines will be filled with fresh water. Take appropriate actions
to prevent freezing of lines. Select System Rinse Mode button and press Auto Start.
System Test Mode: Machine cycles actuated valves and pump on the Main Control panel and checks
operation. If a valve fails, the machine will fault. Select System Test Mode button and press Auto Start.
Simulate Mode: Machine simulates brine production. Brine concentration, and the liquid level in salt tank
are simulated. Caution: Valves will open and close and pump will operate. To run the simulate mode
without the pump running, turn off pump circuit breaker. Close all valves at storage tanks to prevent liquid
from back flowing into system. Close fresh water supply valve to prevent fresh water from being added to
salt tank. This is a good feature for training operators with out actually making product.
To access Mode page, Enter password of 4096, Go to the HOME page and press the Mode button.
57
HMI Switch Box
To access the switch box, enter Password 4096, go to the Home page, and press the Switch button.
Stop Button: Stops the current batch production. This is a momentary button.
Start Button: Starts the current batch production. This is a momentary button.
Remote Fill Button: Has the same functionality as the physical Remote Truck fill button
at fill point. Use if remote switch becomes inoperative.
The HMI Remote Switch Box feature allows operation of the Auto Start, Remote Truck Fill and Stop
switches from the HMI or Webgate from a remote location if a physical switch is damaged.
58
Plumbing Configuration Drawings
Accubrine Model: AB - Brine Production
59
Plumbing Configuration Drawings Cont. Accubrine Model: RTF - Brine Production and Remote Truck Fill
60
Plumbing Configuration Drawings Cont. Accubrine Model: ABS - Brine Production, 1 Additive and Remote Truck Fill
61
Plumbing Configuration Drawings Cont. Accubrine Model: ABS2 - Brine Production, 2 Additive and Remote Truck Fill
Fro
m B
lend P
roduct S
tora
ge T
ank
To A
dditiv
e 2
Sto
rage T
ank
To W
ate
r S
upp
ly
To
Pu
mp Inle
t
To B
rin
e S
tora
ge T
ank
Fro
m B
rine
Sto
rage T
ank
M220BRB90
M2
20
BR
B90
M100BRB90
M100BRB
M1
00
BR
B9
0
To A
dditiv
e 1
Sto
rage
Tank
Fro
m A
dditiv
e 2
Sto
rage T
ank
Fro
m A
dditiv
e 1
Sto
rage T
ank
M2
20B
RB
90
To T
ruck F
ill
MV
22
0C
F
M2
20T
EE
MV
22
0C
FH
To B
lend S
tora
ge T
ank
H
MV
22
0C
F
M220C
R
Fre
sh w
ate
r to
Salt T
ank
Bri
ne R
etu
rn
Bri
ne o
ut
of S
alt T
ank
62
When password 2048 is activated, the HMI configuration, My Settings and, Copy Data to USB features
become available.
Press button to activate “Print” button on all screens. Press green “Print” button to
print current screen if printer is connected. Note: Installed printer must be compatible
with Hewlett Packard PCL 6 driver.
Press button to enlarge video screen if video camera is installed.
Help Screen, HMI Configuration, My Settings, and Copy Data to USB Features
From the HOME screen, press the button. Change password to 2048, then press enter.
63
Press first down arrow and select Opera-
tional Setup, Data Log, or PM Log.
Press the Snapshot Button to capture the machines
current configuration settings. The values for each item
above will populate with the current setting.
Press the Save Button to save the machines
current configuration settings.
Press the Send Button to reload the previously
saved machine settings into the setup pages.
This screen will allow you to take a snapshot of the current machines Operational settings, Data Log Set-
tings, and Preventative Maintenance settings to reload if settings were changed by mistake.
Saving and Reloading Machine Configuration - My Settings
Press first down arrow and select Operational
Setup, Data Log, or PM Log.
Press the My Settings button to access Recipe screen to save and reload current
Operational machine settings.
64
Select this button to download the data collected from production and truck
loading to a portable USB memory stick. Insert a formatted (Fat32) USB
memory stick into the USB port on the side of the HMI enclosure. The
message: USB device is plugged in. Press the “Data Log to USB” button.
Select this button to download the data collected from production and truck
loading to a portable USB memory stick and erase all data stored in internal
memory.
Select this button to download “My Settings” (the brinemakers setup vari-
ables) to a portable USB memory stick.
Copy Data to USB Flash Drive Memory
Install a portable flash drive into the supplied USB connector on side of control panel enclo-
sure. Press button to access the Transfer Data to USB selection page.
Select this button to download the fault data that has occurred, to a portable
USB memory stick.
65
HMI Data Download with LAN or USB Memory Stick
1. Data may be extracted with 2 methods:
a. By direct communication between the Accubrine HMI and a computer with a network
connection (LAN). To download data via LAN connection, Vijeo Designer Data
Manager Software must be loaded onto the target/owners computer.
b. By plugging in a USB flash drive directly into the HMI. (USB port located on the side
of the HMI - see page 64)
2. HMI Data logs are available on a daily basis after midnight. Note that data logs created prior
to midnight will not be available for download until after that time.
3. To download via LAN network the HMI must have the LAN option enabled and you must
connect your PC to the HMI via ethernet cable.
a. Start Vijeo Designer Data Manager.b. Under media, select: New Target Connection
c. Then select Create
66
d. On the Configure Target screen: Name: create a name such as Accubrine data
download (or select a connection previously created).
e. Select: Ethernet
f. Enter the Touch screen/HMI IP address: 196.170.86.54
g. User name: enter accubrineh. Password: enter 4096
i. Data Location: select Secondary Drivej. Select: Create
k. You will be taken back to the previous page
l. Make sure Retreive Files is selected and press Next.
67
m. Select: data loggingn. Press the options button
o. Select: Overwrite if file exists. Caution this will override previous downloaded data.
If previous data is to be stored, save new data in new folder and location.
s. Select: Create a folder
t. CSV/TXT Delimiter, select comma
u. Select: Headerv. Select: Convert time stamp to date string
w. Format type, select: mm/dd/yy
x. Select: Delete files on target (HMI) after retrieval, if desired and press OK.
68
y. Output Folder: Use the preselected desktop location for the output folder or use the
drop down button to select another location on your PC.
z. Press Retrieve
aa. A progress/status page will pop up showing the retrieval process.
bb. When complete, press Close.cc. Retrieval process is complete and you may press Exit to close the Vijeo Designer
Data Manager program.
69
Accubrine Data Manager - RFID and Truckfill Data Extraction Tool
This data extraction tool is used to extract, convert, and report RFID and Truckfill data generated by the
Accubrine system and downloaded to a USB memory stick or PC via LAN access.(See pages 64-68)
The data manager is located on a CD that is supplied with the brinemaker. Follow the installation and
operational instructions on the following pages.
70
Accubrine Data Manager - Installation cont.
71
Accubrine Data Manager - Installation cont.
Please read the license agreement and select “I Agree” to continue the install process.
72
Accubrine Data Manager - Installation cont.
73
Accubrine Data Manager - Installation cont.
74
Accubrine Data Manager - Installation cont.
To start the Accubrine data Manager, double click on the desktop icon or access through the start menu.
If you desire to remove the Data Manager tool, follow the instructions below.
75
76
The input folder must be the LOG folder where all the data log files are stored (USB memory stick or
location where data was stored from LAN access download). Do NOT select an individual folder within
the LOG folder.
77
If the data to be extracted falls within a particular date range, select the filter by date range box, and enter
the date ranges in the boxes below.
Press the convert button and a preview of the data report will be generated. If you choose not to save the
report, select new dates or press the Exit button to end the Data Manager session.
78
To save a copy of the data report, select File, then Save As and select where you want to save the file. You
can then name the file as in the example below. Press the Save button.
79
Settings
180 35010372 10/2006
The following illustration displays System tab on XBT GT4000/5000/6000/7000
series units:
Stylus This setting is not supported for XBT GT1100/1130 series units.
Date/Time The following table describes how to change the date or time on an XBT GT unit.
Restart The following table describes how to force an XBT GT unit to restart.
Language The following table describes how to select the language used by the XBT GT
system (Settings menu and run-time messages) and user application.
Offline System Diagnostics
Stylus Date/Time Restart Language
Ver. Info Memory Brightnes Option
To run Mode
Step Action
1 In the Settings menu, touch the System tab.
2 Touch the Date/Time icon.
3 Touch any of the Date or Time fields and a data entry keypad will display. Use this
keypad to define the selected date or time setting.
Step Action
1 In the Settings menu, touch the System tab.
2 Touch the Restart icon.
3 Touch the Restart button to restart the XBT GT unit.
Step Action
1 In the Settings menu, touch the System tab.
Display Setup
Reprinted with permission from Schneider Electric
Enter password 2048, press the HMI config button from the help page (See pg.42), select Date and Time.
80
Maintenance
192 35010372 10/2006
Regular Cleaning
Introduction The regular cleaning is composed of:
Cleaning the front panel,
Cleaning the Gasket and procedures.
Cleaning the
display
When the surface or the frame of the display gets dirty, soak a soft cloth in water
with a neutral detergent, wring the cloth tightly, and wipe the display.
Cleaning the
Gasket
The gasket protects the XBT GT and improves its water resistance.
A gasket which has been used for a long period of time may have scratches or dirt
on it, and could have lost much of its water resistance. Be sure to change the gasket
at least once a year, or when scratches or dirt become visible.
CAUTIONRISK OF EQUIPMENT DAMAGE
Do not use hard or pointed objects to operate the touch-screen panel, since it can
damage the panel surface.
Do not use paint thinner, organic solvents, or a strong acid compound to clean the unit.
Failure to follow this instruction can result in injury or equipment damage.
Display Maintenance: Cleaning the display
Reprinted with permission from Schneider Electric
81
Maintenance
35010372 10/2006 193
Inserting the
Gasket
The gasket must be inserted correctly into the groove for the XBT GT's moisture
resistance to be equivalent to IP65.
The upper surface of the gasket should protrude approximately 2mm [0.08 inch] out
from the groove. Be sure to check that the gasket is correctly inserted before
installing the XBT GT into a panel.
Note: Be sure the gasket's seam is not inserted into any of the unit's corners. Insert
the joint only in the straight sections of the groove, preferably in the bottom section.
Inserting it into a corner may lead to its eventually tearing.
Reprinted with permission from Schneider Electric
82
Maintenance
194 35010372 10/2006
Periodic Check Points
Introduction To keep your XB GT unit in its best condition, please, check the following points
periodically.
XBT GT Operation Environment,
Electrical Specifications,
Related Items.
XBT GT
Operation
Environment
The operating temperature is within the allowable range (0°C to 50°C) (32°F to
122°F)?
The operating humidity is within the specified range (10%RH to 90%RH), dry bulb
temperature of 39°C (102°F) or less?
The operating atmosphere is free of corrosive gases?
XBT GT
Electrical
Specifications
The input voltage is appropriate?
DC19.2V to DC28.8V.
Related Items Are all power cords and cables connected properly? Have any become loose?
Are all mounting brackets holding the unit securely?
Are there many scratches or traces of dirt on the installation gasket?
Reprinted with permission from Schneider Electric
83
Maintenance
35010372 10/2006 195
Replacing the Backlight
Introduction The XBT GT1000/2000/4000 series units’ backlight cannot be replaced by the
customer. When the backlights need to be replaced, please contact your local
XBT GT distributor.
The XBT GT5000/6000/7000 series units’ backlight can be replaced by the
customer. Please see the Instruction Sheet that comes with replacement backlights
for details on how to replace the backlight. Contact your local XBT GT distributor for
more information.
How to
Determine if the
Backlight is
Burned Out
If your XBT GT unit's backlight suddenly turns OFF, use the following steps to
determine if the backlight is actually burned out:
If the XBT GT unit's "Backlight Control" is not set and the screen has gone blank,
your backlight is burned out.
If the XBT GT unit's "Backlight Control" is set to Standby Mode and the screen
has gone blank, and touching the screen or performing another input operation
does not cause the display to reappear, your backlight is burned out.
WARNINGRISK OF UNINTENDED EQUIPMENT OPERATION
Do not create XBT GT touch panel switches for system functions that may cause
injury and/or equipment damage.
If the XBT GT unit's backlight burns out and the unit is not set to Standby Mode,
the touch panel remains active. If the operator fails to notice that the backlight is
burned out and touches the panel, unintended equipment operation can occur.
Failure to follow this instruction can result in death, serious injury, or
equipment damage.
Reprinted with permission from Schneider Electric
84
Installation and Wiring
152 35010372 10/2006
Precautions When using the XBT GT Unit and a CF Card, follow the precautions below:
Prior to inserting or removing a CF Card, be sure to turn the XBT GT unit’s CF
Card ACCESS switch OFF and to confirm that the ACCESS lamp is not lit. If you
do not, CF Card internal data may be damaged or lost.
Check that the CF Card DIP Switches setting are appropriate.
While a CF Card is being accessed, NEVER turn OFF or reset the XBT GT, or
insert or remove the CF Card. Prior to performing these operations, create and
use a special XBT GT application screen that will prevent access to the CF Card.
Prior to inserting a CF Card, familiarize yourself with the CF Card’s front and rear
face orientation, as well as the CF Card connector’s position. If the CF Card is not
correctly positioned when it is inserted into the Mulit Unit, the CF Card’s internal
data and the XBT GT unit may be damaged or broken.
Be sure to use only CF Cards manufactured by Schneider Electric. XBT GT unit
performance cannot be guaranteed when using another manufacturer’s CF Card.
Once XBT GT data is lost, it cannot be recovered. Since accidental data loss can
occur at any time, be sure to back up all XBT GT screen and CF Card data regularly.
CAUTIONRISK OF EQUIPMENT DAMAGE
Be sure to follow the instructions given below to prevent the CF Card’s internal
data from being destroyed or a CF Card malfunction from occurring:
DO NOT bend the CF Card.
DO NOT drop or strike the CF Card against another object.
Keep the CF Card dry.
DO NOT touch the CF Card connectors.
DO NOT disassemble or modify the CF Card.
Failure to follow this instruction can result in injury or equipment damage.
Reprinted with permission from Schneider Electric
85
Installation and Wiring
35010372 10/2006 153
Inserting the CF
Card
Use the following steps to insert the CF Card.
Step Action
1 Slide the CF Card Cover in the direction shown here, then upwards to open the cover.
2 Insert the CF Card in the CF Card Slot, until the ejector button is pushed forward.
3 Close the cover. (As shown).
4 Confirm that the CF Card Access LED turns ON.
You cannot access to the CF Card with the CF Card cover opened. However, if the CF
Card is being accessed, the access will be continued even if you open it on the way.
HMI Display - Compact Flash Memory Card
Reprinted with permission from Schneider Electric
Remove the rear cover of machines HMI panel to access.
86
Installation and Wiring
154 35010372 10/2006
Removing the CF
Card
Simply reverse the steps shown in the previous "inserting CF Card" explanation.
Prior to removing the CF Card, confirm that the CF Card Access LED is turned OFF.
The following figure displays how to remove the CF Card:
CF Card
Handling
The CF card has a life expectancy of 100,000 write cycles. Therefore, be sure to
back up all CF Card data regularly to another storage media. (100,000 times
assumes the overwriting of 500 kilobytes of data in DOS format).
The following table presents two methods to back up data.
Eject Button
If Then And
Your PC is equipped
with a PC Card Slot
To view CF Card data on a personal
computer, first, insert the CF Card into a CF
Card Adaptor XBT ZGADT.
Save data CF Card
on the PC.
Your PC is not equipped
with a PC Card Slot
Use a standard XBT ZGADT type PC Card
or CF Card reader.
Save data CF Card
on the PC.
Note: Depending on the setup of your PC, it’s possible that the Card reader may
not operate correctly.
The connection between a personal computer and CF Card reader has been tested using
an Windows® compatible machine. Check that CF Card reader is correctly installed and
configured. Please contact your PC or CF Card reader manufacturer directly for details.
Reprinted with permission from Schneider Electric
87
Settings
176 35010372 10/2006
The following illustration shows the Offline tab on XBT GT4000/5000/6000/7000
series units:
Network Buzzer Backlight Self Test
Option IO Manager MultiMediaWeb Gate
To Run Mode
Offline System Diagnostics
Reprinted with permission from Schneider Electric
88
Settings
35010372 10/2006 177
Network Settings The following table describes how to change the network settings (IP address) on
all XBT GT units (except on XBT GT1100).
Touch Buzzer The following table describes how to change the buzzer settings on the XBT GT unit.
Step Action
1 In the Settings menu, touch the Offline tab.
2 Touch the Network icon.
3 Touch any of the three fields (IP Address, Subnet Mask, or Default Gateway) and a
keypad will appear.
4 Enter the desired network addresses.
Note: In order for changes to the network settings to take effect, the XBT GT will
restart when you touch "To Run Mode" and return to the application.
Step Action
1 In the Settings menu, touch the Offline tab.
2 Touch the Buzzer icon.
3 Touch the desired buzzer mode. The factory setting is When Press Touch object.
None: Selecting this will turn the buzzer OFF.
When Press Touch Object: The buzzer will only sound when a Touch Object is
touched.
HMI Display Webgate Setup: Enter password 2048. Select HMI config from same help page.
Reprinted with permission from Schneider Electric
89
From you computer desktop
click start.
Click Settings
Click Network Connections
Click Local Area Connection
90
Click Properties
Use the slide bar and scroll to
the bottom to go to Internet
protocol
double click on internet protocol
91
Click on the small circle. USE the
following IP address
Enter the address of
IP 196.170.86.54
Subnet Mask: 255.255.255.0
Click OK
92
Start windows explorer from the computer desktop by double clicking
the internet explorer icon, this will be located at the bottom of your screen.
When Windows explorer starts, key in the following address: http://196.170.86.55/ , (note after you have
done this once you may be able to start typing 196... and it will appear automatically).
Webgate and communication between your PC and the desktop unit will begin at this point and you
will see the screen below. If you are unable to connect to the HMI, you may have to disable any
firewalls on your PC that are preventing the connection from taking place.
93
To view what is on the
Accubrine desktop:
Click Monitoring
Then Click In Frame
Loading of images will
begin.
94
Right click on the center of the display and a Synchronization button will appear. Click on Synchro-
nization.
At this point what is displayed on the desktop will appear on the computer screen. Use the desktop
display to scroll through the windows as you normally would do.
Note: If using a projector, press the blue function button or Fn and F8 button on you computer keypad.
95
Accubrine Start-up Procedure
• Before firing the machine for the first time. Make sure that power supply is correct. 220V between
the main lugs and 110V between each of the main lugs and neutral. No voltage between neutral and
ground.
• Press each of the black fuse holders located on the terminal blocks in the control panel enclosure, to
make sure they are seated.
• Ensure settings are loaded into PLC, Enter Password 4096 and go to setup page 1. If values are
in, you will see various numeric values. If not, they will all be 0. To reload, go to Home page and
press Help, enter password 2048. Press the My Settings button, to go to the My Settings page.
Press the Send button to load the factory settings into the setup pages. Return to the Setup pages
and verify/turn on appropriate options as machine is equipped. IE: Truck Fill, RFID etc.
• Do not put salt in the Salt Tank at this time.
• Disconnect the hose leading to the Brine storage tank as fresh water will be discharged.
• Close main electrical cover before turning on water supply.
• Verify water supply is off.
• Check and make sure all hose clamps, and manifold clamps are secure.
• Open all 2" valves on Salt Tank and close all 1” and 1/2” cleanout valves.
• Have all valves in normal Automatic position on main panel. All valves on main control panel should
be in the verticle position.
• If equipped with modular panel, place all valve handles in the automatic position.
• Open manual dilute valve on main panel. This helps to prime the pump.
• Turn on water supply and brine maker water supply valves and begin to fill salt tank. Check for
leaks. Fill tank to grate. Monitor water pressure when all valves are closed, and as main water
valve cycles. For optimum performance, pressure should not exceed 40 PSI static at any time to
include spike and hammer (80 PSI max.). If this occurs install a pressure regulator.
• Put machine in Simulate Mode: Enter password 4096 then ESC to Home page then press Mode
then press the Simulate Mode button.
• Start a batch: Home page, press Batch button, key in 150 for quantity. If equipped with additive,
select 0 for the ratio and select tank 1 (Brine).
• Once pump starts and is primed close the manual dilute valve on main panel.
• Check for leaks.
• Reconnect hose leading to the Brine Storage tank.
• Put machine in Normal mode: Enter password 4096 then ESC to Home page then press Mode,
then press Normal Operation Mode. press the Home button.
• Place salt in hopper and produce a batch.
96
Parts: Main control panel, Rear View
Note: Circled part numbers refer to the same parts/HMI callout numbers available on the HMI touch
screen. These are listed on the Complete Parts pages at the back of this manual.
Tank Valve
See page 109.
Water Valve
See page 108.Dilute Valve
See page 107.
Walchem Conductivity
Analyzer.
97
Pedestal Pump Inlet and Outlet with Conductivity Sensor Assembly
98
Salt Tank Water Inlet Valve assembly.
99
Salt Tank Water Spray Assembly
100
Salt Tank Drain Kit - Supplied With Salt Tank
101
Salt Tank Suction Tube Assembly
102
Salt Tank Return Assembly
103
Salt Tank Level Sensor
104
Salt Tank Sump Spray Assembly
105
Salt Tank Side Flush
106
Salt Tank Drain Kit Option
107
Clamps and Required Gaskets
108
Storage Tank Plumbing Assembly
Roll Tarp CoverCargill BM# - 244
109
Discharge Valves from pump to
Storage Tanks & Truck Fill
4 X 4 Modular Panel and Valve Module Example
Suction Valves from Salt tank &
Storage Tanks to Pump
MV220BL, BM-292
ACC1175 - KZ Co., BM-600
M220Y45, BM-361
M220Y45, BM-361
4 X 4 Sub Panel (4 Discharge Valves and 4 Suction Valves)
Electrical Enclo-
sure on Sub Panel
BM-069, Modular Plumbing Module
110
Dilute Valve Assembly, BM -599, KZ CO. #ACC1105
1
2
3
111
2 Way On/Off (Water & Subpanel) Valve Assembly, BM-600, KZ CO.
#ACC1175
1
2
3
112
3 Way Bottom Load (Tank)Valve Assembly, BM-601, KZ CO. #ACC1150
1
2
3
113
Preventative Maintenance Schedule
This Preventative Maintenance page monitors and records number of cycles for the actuated valves, and
hours of operation for the pump head and motor for the main control panel and auxilliary recycled water
pump if applicable.
The blue box indicates the
number of Actual cycles or
hours each valve or pump/
motor has reached.
The Life Cycle box indicates
the number of Expected cycles
for each valve or number of
hours of operation before
routine periodic maintenance
should be conducted. This
may be inspection, rebuild, or
even replacement. The life
cycles for valves is expected to
be 250,000. The hours for the
pump head is excpected to be
500, and the hours for the
motors is expected to be 1000.
The Reset box when pressed,
will reset the actual number of
cycles or hours to 0 when
inspection, rebuild, or replace-
ment has taken place.
Press the P.M. Page 2 button
to access the second page of
valves, pumps, and motors.
To access the Preventative Maintenance page
go to the Help page and press the Preventative
Maintenance button.
114
Trouble Shooting Guide
• Valve Failure - could affect these valves:
Water Valve - Open
Tank Valve – To Return
Optional valves for Remote Fill and Additive injection, Recirculation.
§ The system monitors the valve when in the deenergised position. When the valve
change position contact does not have +24 VDC, the valve goes to its normal state
(white wire to actuator is not energized). When alarm is withnesed, this may be
caused by any of the following scenarios.
1. Power supply failure- Generally several alarms may be activated. All
actuators operate on a 24 VDC circuit, if the power supply fails then a
valve actuator failure may be present.
2. Valve circuit has failed – Wire has come loose:
Refer to wiring diagram to trace to terminals and check all
connections.
3. Fuse Blown –
Use wiring diagram or trouble shoot from the display to find
possible fuses. Note: A blown fuse illuminates red when it has
failed, the fuse holder must be energized to illuminate red depending
on the state of the machine. These circuits may or may not be
energized, therefore physically check all fuses.
4. Actuator failed to change position due to actuator failure.
Replace actuator
5. Valve actuator is changing position but valve position has failed.
Disable alarm and repair or replace actuator.
Fault: 4-20ma Signals
1. Check wiring,and make sure that the signal wire from sensor terminal 2 of the connector at the sensor is
attached to the + terminal of the PLC. Check that terminal 1 to the plug has + 24VDC. Refer to wiring
diagram sent with machine.
2. If Wiring is correct: With the machine energized remove the black plug where the wires land into
the PLC and then reconnect.
3. Reset fault and attempt another batch.
115
Pump Thermal Overload
The pump is activated ON to the run state via a motor starter with a built in thermal overload.
This thermal overload protects the electric motor form excess current draw.
1. Improperly set thermal overload – Adjust thermal overload to amperage rating on
motor do not exceed 110% of motor rating.
2. Low voltage from supply – Since I = E/R as voltage drops, current will increase. Low
voltage at peak periods of use on an electric grid or within the structure may cause this
voltage drop. Solutions may be to isolate circuits to balance the electric load from a
service panel or it might be possible to convert a system to a 3 phase motor in extreme
cases.
3. Pump motor is drawing excess current –
Wear and tear on motor may cause excess friction thus leading to overpower
requirements. This is usually witnessed by a squeak or growling noise from the motor.
Locked or jammed impeller on the pump head.
Pump pumping heavy liquid – with use of the additive injection system, the product
being pumped may be heavier than the pump was designed for.
Concentration: Over and UndershootingThis is witnessed by the concentration of the brine being over tolerance and then under tolerance.
1. This is caused by the machine not being able to dial in a desired concentration. As the
dilute valve adjusts, to much water is added in the dilution process then the valve
adjusts again and not enough water is added.
2. Brine tolerance to tight: Set concentration + or – to 300 or above. Adjust the dilute on
time downward. Ideally it should take12 or more actuations of the dilute valve to
open fully. To test, set the desired concentration of brine to 19.6% and put the
machine in Simulate Mode and make a batch. Watch the dilute valve and count the
number of valve bumps it takes to fully open from the closed position.
3. Excess water pressure – High water pressure may allow an excess amount of water to
pass through the dilute valve. Installing a pressure regulator on the water supply
side limiting the pressure to the 40-50 PSI in a static position will greatly
enhance the dilution performance.
116
Walchem Electrodless Conductivity Analyzer Calibration - Single Point
On setup page 1, set the Target Brine Concentration to 26.2%. This will set the specified concentration on
the concentration graph on the touch screen to the extreme right of the graph.
Set the Target Concentration (+ or -) % to 100. This will narrow the green band on the concentration
graph on the touch screen.
Go to the Batch page and enter 500 gallons.
Press Auto Start. Allow the brine to recirculate to the salt tank for 15 minutes to become fully concentrated
and equalize the temperature of the liquid and conductivity sensor.
Open the manual dilute valve about 1/3rd of full travel.
Take two or three brine samples at the salt tank return hose quick coupler. Open one wing of the coupler to
allow a small stream of brine to leak out. Collect about one cup of brine and test with a hand held salt brine
concentration tester.
If the collected brine concentration is higher than 23.3%, open the dilute valve some more. Open valve in
small increments to prevent under shooting the 23.3% concentration.
If the collected brine concentration is under the 23.3%, close the dilute valve a small amount.
Continue sampling, testing, and adjusting the dilute valve until the concentration is 23.3% + or - 0.1% .
This single point calibration procedure should be used when the operating temperature of the brine, salt and
water are 10 or more degrees above or below normal expected temperatures in the brine making season
(sensor is calibrated at the factory at 38 degrees F.). This procedure will be accomplished with the
brinemaker recirculating brine to and from the salt tank in the batch making process. The concentrated
brine will be diluted manually with the manual dilute valve on the lower front right portion of the brinemaker
control panel Make sure there is plenty of salt and water in the salt tank to fully concentrate the brine and
prevent the fresh water to the top of the salt tank from coming on during this process.
Manual Dilute Valve
117
1. Press the exit button until “conductivity A” is displayed.
2. Press the enter button until calibrate is displayed.
3. Press the enter button.
4. Press the enter button.
5. Use the left and right arrow buttons, to move the flashing cursor to the correct positions and
the up and down arrows to enter the value of sample concentration taken earlier. For Ex. 23.3
6. Press the enter button twice.
7. Press the exit button. The Single-point Calibration process is complete.
8. The concentration on the analyzer and touch screen should now read very close to 23.3%.
9. Go to the setup page 1 and return the Target Brine Concentration setting back to 23.3%
10. Return the Target Concentration (+ or -) % back to 350 or 0.6%.
11. Let the 500 gallon batch complete and monitor the machines performance.
When the brine sample is at the 23.3% concentration, perform the calibration procedure on the Walchem
Conductivity Analyzer located on the back right side of the control panel. Open the clear plastic cover.
Walchem Electrodless Conductivity Analyzer Calibration - Single point cont.
If this procedure does not improve the accuracy of the brine concentration, refer to the 3 point calibration
section on the next page and perform that process.
118
Purpose: This 3 point calibration procedure should be performed at machine installation, and when the
operating temperature of the brine, salt and water are 10 or more degrees above or below normal expected
temperatures in the brine making season (sensor is temperature calibrated at the factory at 38 degrees F.).
This procedure will be accomplished with the brinemaker recirculating brine to and from the salt tank in the
BATCH making process. The concentrated brine will be diluted MANUALLY with the manual dilute valve
on the lower front right portion of the brinemaker control panel to CREATE brine liquids of a specific
concentration. Make sure there is plenty of salt and water in the salt tank to fully concentrate the brine
during this process.
Creating Specific Concentration Liquids Procedure:
1). On the Accubrine touch screen, with password 4096 activated, go to setup page 1, set the Target Brine
Concentration to 26.2%. This will set the specified concentration range on the concentration graph to the
extreme right of the graph.
2). Set the Target Concentration (+ or -) % to 100. This will narrow the green band on the concentration
graph on the touch screen.
3). Close the 2" fresh water valve on the salt tank to prevent water from entering the salt tank during the
calibration process.
4). Go to the Batch page and enter 500 gallons.
5). Press Auto Start. Allow the brine to recirculate back to the salt tank for 15 minutes to become fully
concentrated and equalize the conductivity sensor to the temperature of the liquid.
6). Open the manual dilute valve about 1/3rd of full travel. Note: This process allows us to CREATE the 3
calibrating solutions.
7). Take two or three brine samples at the salt tank return hose quick coupler by opening ONE wing of the
coupler to allow a small stream of brine to leak out. Collect about one cup of brine and test with a hand
held salt brine concentration tester.
If the collected brine concentration is higher than 22.0%, open the dilute valve a small amount. Note:
Open the dilute valve in small increments to prevent under shooting the 22.0% concentration.
If the collected brine concentration is under the 22.0%, close the dilute valve a small amount.
Continue sampling, testing, and adjusting the dilute valve until the concentration is 22.0% + or - 0.1%.
Walchem 410 series Electrodless Conductivity Analyzer Calibration - 3 point
119
Walchem 410 Sensor Calibration: When the brine sample is at the 22.0% concentration, enter the multi
point calibration screen on the Walchem Conductivity Analyzer located on the back right side of the control
panel.
A. Press the exit button until the % concentration and SENSOR is displayed on the analyzer screen.
B. Press the enter button and then the next button until CALIBRATE is displayed.
C. Press the next button until MULTI POINT is displayed.
D. Press the enter button.
E. Use the UP arrow button to change the 2 to a 3 and press enter. If the analyzer asks you to RINSE
SENSOR, press next. The analyzer will then ask you to put the sensor into the first solution.
With the machine running and the dilute valve metering in fresh water, we created the FIRST
solution of 22.0%
F. Use the left and right arrow buttons, to move the flashing cursor to the correct positions and the up
and down arrows to enter the value of sample concentration taken earlier. For Ex. 22.0
G. Press the enter button to enter the first actual sample concentration into the analyzer.
H. Press the enter button when the conductivity reading (in MS – Milli-Siemens) stabilizes.
Approximately 10 seconds. The analyzer display will now ask you to place the sensor into the
second solution.
I. Return to step 7 and repeat above procedure to CREATE and ENTER the next solution of 23.3%
and then 24.5%.
J. When all three solutions have been entered into the analyzer, CAL SUCCESSFUL will be displayed.
If an error message occurs, repeat the multi-point calibration process.
K. Press the exit button until the concentration and temperature are displayed. The concentration on the
analyzer and touch screen should now read very close to 23.3%.
L. Go to the setup page 1 and return the Target Brine Concentration setting back to 23.3%
M. Return the Target Concentration (+ or -) % setting back to 350 or 0.6%.
N. Let the 500 gallon batch complete and monitor the machines performance.
Walchem Electrodless Conductivity Analyzer Calibration - 3 point cont.
120
Main Control Panel Automatic Valve Position .
1. Close the Manual Overide
valves for the Brine Out and
Fresh Water to direct flow to
the manual valves and away
from the electric valves.2. Open the Tank valve if
brine is at the desired
concentration to send to
storage tank.
3. Open the Return
valve if brine is lower
than the desired
concentration and
send back to salt
tank.
4. Open the Water Dilute
valve slowly if brine is higher
than the desired concentra-
tion.
5. Open the Brine Maker
Water Supply valve to add
water to the salt tank.
The valves are shown in the normal auto position. The manual positions can be used in the event of an
actuated valve failure. To make brine manually, follow the steps below
121
Main Control Panel and Sub Panel - Additives and Remote Fill Valve Positions
Automatic position:
Normal operation
Manual position: Opens
valve to direct flow to the
same location as the electric
valve. Turn handle 180
degrees.
Half Way between the
Manual and Automatic
position: This position blocks
flow to the electric valve.
Note: The electric valves fail
in the open position.
All valves are shown in the automatic position. The manual positions can be used in the event of an actuated
valve failure. To make brine manually, see previous page for valve positions on main panel. The valve
positions for the modular panel, regardless of function are illustrated below.
122
Accubrine ™ Automated Brine maker - Salt Tank Cleanout Procedure
Periodic cleaning and removal of sediment and debris from the salt tank is required to keep the brine maker
operating efficiently. Before cleaning the salt tank, it’s best to have the salt level as low as possible to prevent
the salt from becoming a hard layer, and prevent corrosion from forming on the screen during storage. With
three inches or less of salt remaining on the screen, the screen can be removed from the salt tank with the
supplied nylon straps. Use care when removing as damage may occur to screen or salt tank. Clean off salt
screen and return to salt tank after tank cleanout.
A. Lowering the brine level in Salt Tank
1. Input password 4096
2. Go to Set up page 1
3. Take note of the “pump-off setting”. Set pump-off to a value of “50”.
4. Close the 2" water supply valve on the end of the salt tank to prevent more water from being added.
5. Run a small batch of 500 gallons of brine. The machine will send brine to the storage tank. (Increase
“Target Concentration + or -” setting to allow brine to be sent to storage tank.) Very Important!!! The
sound of the pump will change when the liquid level gets below the suction lines to the pump. Have
someone shut off system as soon as pump change is heard prevent damage to the seals of the pump.
6. This will lower the liquid level to the suction line on the salt tank. Return to setup page one and set the
“pump-off setting” and “Target Concentration + or -” to original settings.
B. Cleaning the Salt Tank & Sump
1. Open the “Water Manual Override” valve on the control panel to send water to the
salt tank. Clean sides of the salt tank with a brush and water to remove deposits.
2. Close the 2" water valve on salt tank, located on end of salt tank.
2. Remove 4" drain cover on front of the salt tank. Caution: A large volume of liquid will flow through the
fitting when cap is removed. If valve is installed, use loader bucket to remove liquid if desired.
3. Open the (2) 1" Valves located next to the 2" water valve on salt tank valve bank.
4. Open the (2) 1" Valves located on the lower portion on the front side of salt tank for the spray bars to
move sediment into sump.
5. Open the (3) 1/2" valves located on the lower back side of the salt tank for the sump nozzles to move
sediment out of sump through the 4" cleanout.
6. When water flushing from the sump is clean, the sump cleaning process is complete.
7. Close the “Water Manual Override” valve on the control panel.
8. Open the 2" Water valve on Salt Tank.
9. Wait 1 minute and close the lower (2) 1" valves on front of salt tank and (3) ½”
valves on rear of salt tank. This allows the cleanout lines to drain completely.
10. Close the (2) 1" valves located next to the 2" water valve on end of salt tank.
11. Go to Setup page 1 on the HMI display. Reset the “Sump Clean Out” button.
12. Reset password to 10 to prevent tampering.
Important: When the cleaning process is finished, allow the salt tank fresh water and
cleanout lines to drain completely. Failure to do so could cause freeze damage.
The Accubrine™ Automated Brinemaker salt tank is now ready to start the brine making process. Make sure
all valves are in correct operating position if starting a brine batch. Prime the pump with manual dilute valve
before starting pump. This will prevent damage from running pump dry.
123
Accubrine ™ Automated Brine maker Off Season Storage Procedure
Before cleaning the Salt Tank, it’s best to have the salt level as low as possible to prevent the salt from
becoming a hard layer, and prevent corrosion from forming on the screen during storage. With three inches
or less of salt remaining on the screen, the screen can be removed from the salt tank with the supplied nylon
straps. Use care when removing as damage may occur to screen or salt tank. Clean off salt screen and
return to salt tank after tank cleanout.
A. Lowering the brine level in Salt Tank
1. Input password 4096
2. Go to Set up page 1
3. Take note of the “pump-off setting”. Set pump-off to a value of “50”.
4. Close the 2" water supply valve on the end of the salt tank to prevent more water from being added.
5. Run a small batch of 500 gallons of brine. The machine will send brine to the storage tank, (Increase
“Target Concentration + or -” setting to allow brine to be sent to storage tank.) Very Important!!!
The sound of the pump will change when the liquid level gets below the suction lines to the pump.
Have someone shut off system as soon as pump change is heard prevent damage to the seals of the
pump.
6. This will lower the liquid level to the suction line on the salt tank. Return to setup page one and set
the “pump-off setting” and “Target Concentration + or -” to original settings.
B. Cleaning the Salt Tank & Sump
1. Open the “Water Manual Override” valve on the control panel to send water to the
salt tank. Clean sides of the salt tank with a brush and water to remove deposits.
2. Close the 2" water valve on salt tank, located on end of salt tank.
2. Remove 4" drain cover on front of the salt tank. Caution: a large volume of liquid will flow through the
fitting when cap is removed. If valve is installed, use loader bucket to remove liquid.
3. Open the (2) 1" Valves located next to the 2" water valve on salt tank valve bank.
4. Open the (2) 1" Valves located on the lower portion on the front side of salt tank for the spray bars
to move sediment into sump.
5. Open the (3) 1/2" valves located on the lower back side of the salt tank for the sump nozzles to move
sediment out of sump through the 4" cleanout.
6. When water flushing from the sump is clean, the sump cleaning process is complete.
C. Accubrine™ Control Panel and Pump Cleanout Procedure Using Simulate Mode
1. Close 4" cleanout valve or reinstall cap on salt tank.
2. Verify that all 2" valves (three) on salt tank are open.
124
1. Open the “Brine Maker Water Supply” valve on lower left front of control panel. This will put fresh
water back into salt tank. Fill salt tank until water level is about 2 inches above screen.
2. Close the “Brine Maker Water Supply” valve.
3. Close the valve on the brine storage tank and disconnect hose from tank. This will prevent fresh
water from entering the storage tank. Put end of hose on ground where water can be discharged.
4. Open the manual “Water Dilute” valve on the bottom right portion of the control panel (this will
make sure the pump is primed for the next step).
5. Move the “To Salt Tank” valve handle on the subpanel from “Automatic” to “Manual”. This will
open the path to recirculate the water back to salt tank.
6. On the control panel, turn the Hand-Off-Auto switch to the Hand position. This will start the pump.
Run for 20 seconds to prime the pump.
7. Turn the Hand-Off-Auto switch to the center (off) position.
8. Turn off the manual “Water Dilute” valve on the bottom right portion of the control panel.
9. Return the “To Salt Tank” valve handle on the subpanel from “Manual” to “Automatic”.
10. Enter password 4096 and then return to the main page.
11. Press the “Mode” button to go to the mode page.
12. Select “Simulate Mode”
13. Return to the main page.
14. Press the “Batch” button and enter a batch of 200 gallons.
15. Press “Auto Start”. This will simulate a batch of brine being made.
16. When the “Simulated” concentration enters the “Green” range on the touch screen, the automatic
valves to the Brine Storage Tank will open and flush the lines and valves with fresh water.
17. When the concentration enters the “Green” range, open the manual Remote Truck Fill valve and
turn the Remote Truck Fill switch to “On”. This will flush the Truck Fill automatic valves on the
subpanel and lines.
18. Return to the Batch page and press “Stop”.
19. Go to the main page and Press the “Mode” button to go to the mode page.
20. Select “Normal Mode”
21. Return to the main page.
22. Manually drain Salt Tank and all storage tank lines.
23. Reconnect hose to Brine Storage Tank.
24. Close “Water Manual Override” valve on control panel.
25. Open the 2" Water valve on Salt Tank.
26. Wait 1 minute and close the lower (2) 1" valves on front of salt tank and (3) ½”
valves on rear of salt tank. This allows the lines to drain completely.
27. Close the (2) 1" valves located next to the 2" water valve on end of salt tank.
28. Go to Setup page 1 on the HMI display. Reset the “Sump Clean Out” button.
29. Reset password to 10 to prevent tampering.
Accubrine ™ Automated Brine maker Off Season Storage Procedure Cont.
125
Important: When the cleaning process is finished, allow the salt tank fresh water and
cleanout lines to drain completely. Failure to do so could cause freeze damage.
D. Accubrine™ Control Panel leaks and stainless steel cleaning
1. Look for any leaks on the control panel and subpanel. Replace any pinched or damaged gaskets.
Tighten any loose hose or fitting clamps snugly.
2. Use a high quality stainless steel cleaner on all stainless steel parts to clean and prevent corrosion.
WD-40 also works very well.
3. It is not necessary to turn the power off to the machine. Leaving the power on to the machine will
help prevent moisture from entering the control cabinet. The touch screen will go into screen saver
mode.
The Accubrine™ Automated Brinemaker is now ready to store for the season.
Accubrine ™ Automated Brine maker Off Season Storage Procedure Cont.
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Complete Parts List
The HMI Callout Numbers listed below are the same as the circled number in the Parts pages available on
the HMI touch screen. The BM # is the Cargill inventory/order number. To order parts, call the Accubrine
call center at 1-866-900-7258
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Date of Claim:
Claim #:
Owner Information: Claimant Information:
Owner Name: Claimant Name: Owner Address: Claimant Address:
Owner Phone: Claimant Phone: Owner Fax number: Claimant Fax number: Owner E-mail: Claimant E-mail:
Brine Maker Information: Tank Serial Number:
Control Panel Serial #: Brine Maker Location:
Part in Question: Description of Part: _____________________________________ (Include digital pictures as well, if applicable) Location of Part on unit: _____________________________________
Manufacturer Part Number: _____________________________________
Cargill Part Number: _____________________________________
Issue Claimed: (Describe in detail, include probable cause)
FOR DEALER USE ONLY
Will you need assistance with installing the part? Yes ? No ? Labor ($/hr) __________________ Part cost (if applicable) ($) _____________ Travel Time: ($/hour) __________________ Shipping (if applicable) ($) _____________ Mileage ($.xx/mile) __________________
AB204 11/10/09
For Internal Cargill Use Only:
Claim Number________________ Original Ship Date: _____________
Disposition of Claim: ____________
Approved By: _______________
Please remit by mail, fax or email to: Cargill Deicing Technology Phone: 866-900-7258
Attn: Warranty Department Fax: 440-716-4732 24950 Country Club Blvd, Suite 450 Email:[email protected]
North Olmsted, OH 44070
Warranty Claim Form
Warranty Claim Form
Return Mater ials Authorization Form
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